Foundry Metallurgy is the subject of semester V of Anna University B.E Material Science And Engineering Syllabus. In this article, we are glad to provide the syllabus of the foundry metallurgy part of Semester V Subjects in the first-year course.
We intend to provide the subject code ML3501 – Foundry Metallurgy syllabus based on regulation 2021 by Anna University. You can get an idea of the topics in the syllabus of the foundry metallurgy. We hope that the absolute idea on the syllabus will assist the students in avoiding confusion of revision according to weightage. We also include required textbooks and references. If you require anything regarding the syllabus you can comment in the below section. Hope you like this information. Don’t forget to share.
If you want to know more about the syllabus of B.E. Material Science And Engineering connected to an affiliated institution’s four-year undergraduate degree program. We provide you with a detailed Year-wise, semester-wise, and Subject-wise syllabus in the following link B.E. Material Science And Engineering Syllabus Regulation 2021 Anna University.
Aim Of Objectives:
The main learning objective of this course is to prepare students for:
- Getting acquainted with the various patterns, moulding materials and furnaces used in foundries.
- Choosing molding process for casting components.
- Designing gating system for castings.
- Making use of basics of ferrous casting metallurgy for casting quality ferrous castings.
- Making use of basics of non-ferrous casting metallurgy for casting quality nonferrous castings.
ML3501 – Foundry Metallurgy Syllabus
Unit – I: Pattern, Moulding Materials, Furnaces
Introduction to foundry process – Pattern, types – allowances – selection of pattern materials, – Sand Core for foundry applications – types, properties of prepared sand – Moulding and Cores additives preparations – Types of furnaces – Crucible, Cupola, Oil fired furnaces, Electric furnaces, Arc and Induction types.
Unit – II: Moulding Processes
Green Sand -Hand Moulding, Jolt Squeeze and High Pressure Moulding, – CO2 and Nishiyama process – No Bak e- Two part and Three-part Process, – Shell – Investment Casting – Permanent Moulding – Pressure Die casting processes – Ceramic – Plaster of Paris – Centrifugal – Squeeze Electro Magnetic – Lost Foam process.
Unit – III: Design Of Gating System
Design of Gating Systems –Types – Pressure & Un pressurized systems – Sprue – runner – gates – problems in design and manufacture of thin and unequal Sections – designing for directional solidification – Riser design – Chvorinov’s rule, Caines – Section Modulus – Naval Research Laboratory methods, feeding distances – Calculations and number of Risers required, chills and feeding aids – Exothermic And Insulating sleeves Design problems of L, T, V, X and Y junctions, Computer Applications in casting design — Software for casting design CAE – Stress, Liquid metal flow and solidification analysis.
Unit – IV: Ferrous Cast Alloys
Solidification of pure metals and alloys and eutectics – Nucleation – Growth Process, Critical nucleus size – Super cooling – Niyama Criterion – G/R ratio – Cell – Dendritic – Random dendritic structure Segregation and Coring – Eutectics – Compositions and alloys in Cast Irons, FG-CGI- SG structures, Metallic Glass – Mold dilation, Mold metal reactions – Structure and Section sensitivity Cast irons family & microstructures – Alloying effects – Malleable Iron, ADI, Charge calculations – Effect of normal elements and alloying elements in steels – Compositional aspects and properties of alloy steels melting procedure and composition control for carbon steels – low alloy steels – stainless steels composition control – slag-metal reactions – desulphurization – dephosphorisation, specifications for carbon steels – low alloy steels and stainless steels.
Unit – V: Non-Ferrous Cast Alloys
Copper – Aluminium – Magnesium – zinc – Nickel base alloys – melting practices – Al alloys, Mg alloys, Nickel alloys, Zinc alloys and copper alloys – modification and grain refinement of Al alloys – problems in composition control – degassing techniques -Heat Treatment of Aluminium alloys – Basics of Solution and Precipitation process. – Applications of Aluminium Alloy castings in various fields. Residual Stresses – defects in castings.
Text Books:
- A.K.Chakrabarthi ‘Casting Technology and Cast Alloys, Prentice Hall of India
- Heine R W, Loper C R and Rosenthal P C, “Principles of Metal Castings”, Tata McGraw Hill, 2017.
References:
- Manufacturing Technology – Foundry, Farming and Welding | Volume 1 | 5th Edition, P N Rao, McGraw-Hill Education 2018.
- ASM Metals, Handbook “Casting”, Volume 15, ASM International, 2007.
- Beeley P, “Foundry Technology” Butterworth-Heinemann London, 2001.
- John Campbell, “Casting”, Butterworth – Heinemann, 2003.
- The Foseco “Foundryman’s Handbook”, Pergamon Press, 2007.
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